Collision sensor assembly for a stationary structure

ABSTRACT

A collision sensor assembly is attachable to a stationary structure such as a pallet rack, a door frame, the corner of a wall, or the like. The collision sensor is configured to sense when a collision occurs with the stationary structure such as when a piece of movable machinery contacts the stationary structure. The collision sensor assembly includes a sensor operatively connected to a processor which determines when a collision occurs, and produces a signal to an output signal generator to provide an external indication of the collision.

FIELD OF THE INVENTION

The present invention is directed to a collision sensor, and moreparticularly, to a sensor that registers when a stationary structure hasbeen hit or received some other collision.

BACKGROUND OF THE INVENTION

In manufacturing, shipping, storing, and other industries, warehousesare often used for storing pallets of goods. The pallets are typicallystored on pallet racks or other stationary structural member havingsufficient strength to carry heavy loads as well as being able towithstand loading and unloading of the pallets at different levels. Handtrucks, hand lifts, forklifts, and the like are typically used totransfer pallets from one location to another and to position thepallets on or below the pallet rack.

These transport machinery can sometimes contact or otherwise crash intothe pallet racks as they are often awkward or difficult to maneuverwithin small spaces between pallet racks. Such accidents can causesevere damage to the pallet racks that would otherwise make the palletracks unstable or unable to withstand loads thereon. Unless the accidentis reported, there may not be any visual indication that the structuralintegrity of the structure has been compromised.

Powered machinery such as forklifts may include their own collisionsensor, the valuables in a warehouse or business is often the goodsstored therein or the structure itself. The collision sensor(s) on thepowered machinery only provide an on-board warning, but does notindicate which structure within a building or the like has beencontacted, so a manager or structural supervisor may not be able todetermine which stationary structure was struck by the machinery.

BRIEF SUMMARY OF THE INVENTION

A need therefore exists for a collision sensor for sensing when asubstantially stationary structure has been contacted by movingmachinery. The collision sensor is configured to generate at least oneoutput signal to provide a warning or other external indication that thestructural integrity of the stationary structure needs to be examined.

In one aspect of the present invention, a collision sensor assemblyattachable to a stationary structure is provided. The collision sensorassembly includes a housing attachable to the stationary structure. Aprocessor is located within the housing. At least one sensor isoperatively connected to the processor, wherein the sensor senses acollision with the stationary structure. An output signal generator isoperatively connected to the processor. The output signal generatorprovides at least one external indication of the collision.

In another aspect of the present invention, a collision sensor assemblyattachable to a stationary structure is provided. The collision sensorassembly includes a housing attachable to the stationary structure. Aprocessor is located within the housing. A sensor is positioned withinthe housing. The sensor is operatively connected to the stationarystructure and the processor, wherein the sensor senses a collision withthe stationary structure. An output signal generator is operativelyconnected to the processor. The output signal generator provides atleast one external indication of the collision.

Advantages of the present invention will become more apparent to thoseskilled in the art from the following description of the embodiments ofthe invention which have been shown and described by way ofillustration. As will be realized, the invention is capable of other anddifferent embodiments, and its details are capable of modification invarious respects.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

These and other features of the present invention, and their advantages,are illustrated specifically in embodiments of the invention now to bedescribed, by way of example, with reference to the accompanyingdiagrammatic drawings, in which:

FIG. 1 is a pair of exemplary collision sensor assemblies attached tostationary structures;

FIG. 2 is a schematic of a collision sensor assembly.

It should be noted that all the drawings are diagrammatic and not drawnto scale. Relative dimensions and proportions of parts of these figureshave been shown exaggerated or reduced in size for the sake of clarityand convenience in the drawings. The same reference numbers aregenerally used to refer to corresponding or similar features in thedifferent embodiments. Accordingly, the drawing(s) and description areto be regarded as illustrative in nature and not as restrictive.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1, a stationary structure 10 having a collision sensor12 operatively connected thereto is shown. The stationary structure 10can be any non-moving structure such as a building wall, door frame,pallet rack for holding pallets of goods. The term “stationarystructure” is intended to mean any structure that is permanentlystationary or other structure that is otherwise intended to remainsubstantially stationary for extended periods of time and may or may notbe movable. The collision sensor assembly 12 is configured to sense acollision of a secondary object—such as a fork lift, a lift truck,machinery, or other moving object—with the stationary structure 10 andto generate an output for indicating such a collision has occurred.

The stationary structure 10, shown as a pallet rack 14 in FIG. 1, is astructure that is part of a building or within a building, wherein thestationary structure 10 is susceptible to damaging collisions frommovable machinery. For example, a pallet rack within a warehouse iscontinually susceptible to being hit, scraped, or otherwise contacted bya hand truck, hand lift, fork truck, or other movable machinery used toremove, reposition, or otherwise move pallets within the warehouse forstorage on the pallet rack 14. Although not all contact with thestationary structure 10 is damaging such that the extent of the damagerequires significant repair or replacement, the collision sensorassembly 12 can be configured to generate an output signal to indicatethat any severity of a collision has taken place, thereby allowingpersonnel to examine the stationary structure 10 to evaluate the extentof the damage caused by the collision and the structural integrity ofthe stationary structure 10. The collision sensor assembly 12 can alsobe configured to generate an output signal to indicate the location ofthe collision with respect to either the physical location within thebuilding or the physical location on the stationary structure 10 thatwas contacted. The stationary structure 10 can be repairable,replaceable, or even removable as a result of a collision therewith. Inan embodiment, the stationary structure 10 may include at least onecorner, or edge, by which machinery, equipment, or other movablemachinery can contact while moving from around or by the stationarystructure 10. Although the exemplary pallet rack 14, shown in FIG. 1, isin a high-traffic area and/or have a corner or edge around whichmachinery is often moved, it should be understood by one of ordinaryskill in the art that the stationary structure 10 can also include wallsor other elongated non-corner structure that is likewise susceptible tocollision with a moving object.

As shown in FIG. 1, the collision sensor assembly 12 includes a housing16 that is attachable to the stationary structure 10. In one of theillustrated exemplary embodiments, a sensor 18 is spaced-apart from thehousing 16 and is attached to the stationary structure 10. The sensor 18can be positioned at a location that would likely be contacted during acollision, or any other location on the stationary structure 10 thatwould allow the sensor 18 to determine when a collision with thestationary structure 10 has occurred. The housing 16 can be located atany position along the height of the stationary structure 10, therebykeeping the housing from being contacted during a collision whilelocating the sensor 18 at a position along the height of the stationarystructure 10 that would likely be contacted during a collision. Inanother of the illustrated exemplary embodiments, the sensor 18 isintegrally positioned within the housing 16 such that the sensor 18 isoperatively affixed to the stationary structure 10 when the collisionsensor assembly 12 is attached to the stationary structure 10. Thecollision sensor assembly 12 having the integrated sensor 18 can bepositioned near or close to the floor, or any other position along theheight of the stationary structure 10 that would likely be contacted ina collision with the stationary structure 10. The collision sensorassembly 12 also includes a processor 20 and an output signal generator22 positioned within the housing 16.

The sensor 18 of the collision sensor assembly 12 is configured tomeasure when a collision has occurred with the stationary structure 10to which the assembly is attached and generate an output signalindicating such a collision has taken place. The sensor 18 can bedirectly or indirectly attached to the stationary structure 10, providedthat the sensor 18 can sense a collision. The sensor 18 can be anymechanical, electrical, chemical or other commonly known sensor that iscapable of registering a collision with the structure to which it isattached. Exemplary sensors may include an accelerometer, voltagesensor, strain gauge, laser sensor, proximity sensor, vibration sensor,magnetic sensor, and the like. The sensor 18 is configured to sense achange in state, or otherwise determine that a collision with thestationary structure 10 has occurred. The collision sensor assembly 12may include one or more sensors 18 operatively connected thereto. Forexample, the collision sensor assembly 12 may include a sensorattachable to each leg of a pallet rack 14, wherein each sensor 18 isoperatively connected to the collision sensor assembly 12 for detectingwhen any leg of the pallet rack 14 has been contacted. A collisionsensor assembly 12 may also include multiple sensors 18 of differenttypes operatively connected thereto. For example, a collision sensorassembly 12 includes an accelerometer as well as a strain gauge, whichcan increase the likelihood of detecting a collision with the stationarystructure 10. In an embodiment, the sensor 18 is connected to theprocessor 20 by a wire or other electrical connection, wherein thesensor 18 is powered by the processor. In another embodiment, the sensor18 is wirelessly connected to the processor 20, and the sensor 18 caninclude an independent power source. When the sensor 18 senses acollision, a signal (or a change in signal) is transmitted to aprocessor 20 positioned within the housing 16. The signal generated bythe sensor 18 may provide information that a collision has occurred, adamaging collision has occurred, the location of the collision along thevertical height of the stationary structure 10, or the like.

The processor 20 is configured to receive a signal from the sensor 18(or sensors) operatively connected thereto. The processor 20 determineswhere there has been a change in state of the sensor 18 or otherwisedetermines when there has been a collision with the stationary structure10 to which the collision sensor assembly 12 is connected. The processor20 receives at least one signal from a sensor 18 and is configured toeither provide continuous monitoring of the sensor 18 or passivelymonitor the sensor 18. Passively monitoring the sensor 18 may includeonly processing the signal from the sensor 18 when the sensor transmitsa signal to the processor 20. When the processor 20 determines that acollision has occurred with the stationary structure 10 to which thecollision sensor assembly 12 is attached, a signal is transmitted to anoutput signal generator 22 so that the output signal generator 22generates an output signal from the collision sensor assembly 12 toindicate to a user, operator, or another system that a collision hasoccurred.

The output signal generator 22 is configured to generate an externalindication that a collision with the stationary structure 10 hasoccurred. In an embodiment, the output signal generator 22 is a lightattached to the housing 16 that is turned on after a collision. Thelight indicates to a user that the stationary structure 10 needs to beexamined to determine the extent of the damage caused by the collision,and the light should remain on until such examination has taken place.In another embodiment, the output signal generator 22 is integral withor separate from the processor 20 and is an email or text messagegenerator that sends an email and/or text message to a user thatindicates that a collision with the stationary structure 10 hasoccurred. The wireless email and/or text message generator can alsoindicate the particular stationary structure 10 that has been in acollision and/or the location on the particular stationary structure 10that has been in a collision. In a warehouse in which a collision sensorassembly 12 is attached to each pallet rack 14, the email and/or textmessage that indicates the particular pallet rack 14 that has beencontacted is particularly helpful to reduce or eliminate the need toexamine each pallet rack 14 for damage. The email and/or text messagemay also indicate the location on the pallet rack 14 that was contactedduring the collision as well as whether or not there was damage to thepallet rack 14. The output signal generator 22 can also be configured torepeatedly send emails and/or texts indicating a collision in certainintervals of time until the stationary structure 10 has been examinedand the output signal generator 22 can be reset. In a furtherembodiment, the output signal generator 22 may be a warning siren. Inanother embodiment, the output signal generator 22 can produce multipleexternal indications of a collision. In yet a further embodiment, theoutput signal generator 22 may be configured to send a signal or messageto a remote computer or processor for further processing, reading, orother data management. For example, some distribution centers utilizewarehouse management systems that utilize software that direct andcoordinate the movement of goods within the distribution center as wellas movement of goods in shipping. The output signal generator 22 can beoperatively connected to such a system, wherein the output signalgenerator 22 provides an output signal or output data to the warehousemanagement system (and/or the software) to indicate a collision. Itshould be understood by one of ordinary skill in the art that theseembodiments of external indicia produced by the output signal generator22 are merely exemplary and that any type of external indicia can beused to indicate that a collision with the stationary structure 10 hasoccurred.

In an embodiment, a collision sensor assembly 12 is attached to eachstationary structure 10 to monitor and determine when the structure hasbeen in a collision and to provide an external indication of such acollision. In another embodiment, each collision sensor assemblies 12are connected to a network that is configured to collect data from eachof the collision sensor assemblies 12 for continual monitoring of thestatus of each stationary structure 10 within a building or warehouse.

The collision sensor assembly 12, as illustrated in the schematic ofFIG. 2, includes a sensor 18 operatively connected to a processor 20,and the processor 20 is operatively connected to an output signalgenerator 22. The processor 20 and output signal generator 22 can bepositioned within the housing and the sensor 18 is positioned in aspaced-apart manner relative to the housing 16, as shown in FIG. 2. Inanother embodiment, the sensor 18 is positioned within the housing 16.The collision sensor assembly 12, including the sensor 18, is releasablyattachable to a stationary structure 10.

While preferred embodiments of the present invention have beendescribed, it should be understood that the present invention is not solimited and modifications may be made without departing from the presentinvention. The scope of the present invention is defined by the appendedclaims, and all devices, processes, and methods that come within themeaning of the claims, either literally or by equivalence, are intendedto be embraced therein.

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 15. A collisionsensor assembly comprising: a housing releasably attachable to a palletrack, said pallet rack being a stationary structure; at least one sensorfor sensing a collision between a secondary object and said pallet rack,said at least one sensor being operatively connected to said housing; aprocessor positioned within said housing, wherein said processorreceives an output signal from each of said at least one sensors inresponse to said collision; and an output signal generator operativelyconnected to said processor, said output signal generator generating atleast one external indication in response to said collision.
 16. Thecollision sensor assembly of claim 15, wherein said at least one sensoris at least one of an accelerometer, a voltage sensor, a strain gauge, alaser sensor, a proximity sensor, a vibration sensor, and a magneticsensor.
 17. The collision sensor assembly of claim 15, wherein said atleast one sensor includes two or more different types of sensors. 18.The collision sensor assembly of claim 15, wherein said at least onesensor includes at least two of the same type of sensor.
 19. Thecollision sensor assembly of claim 15, wherein at least one of said atleast one sensors is wirelessly connected to said processor.
 20. Thecollision sensor assembly of claim 15, wherein said processor passivelymonitors said at least one sensor for said output signal in response tosaid collision.
 21. The collisions sensor assembly of claim 15, whereinsaid processor actively monitors said at least one sensor for saidoutput signal in response to said collision.
 22. The collision sensorassembly of claim 15, wherein said at least one external indication fromsaid output signal generator is at least one of an audible sound, avisible warning, and an electronic message.
 23. The collision sensorassembly of claim 15, wherein said output signal generator generates awireless output data signal indicating said collision.
 24. The collisionsensor assembly of claim 23, wherein said wireless output data signal isa text message or an email message.
 25. The collision sensor assembly ofclaim 23, wherein said wireless output data signal is received by anapplication on a wireless handheld device.
 26. A collision sensorassembly comprising: a housing releasably attachable to a pallet rack,said pallet rack being a stationary structure; a sensor for sensing acollision between a secondary object and said pallet rack, said sensorbeing operatively connected to said housing; a processor operativelyconnected to said housing, wherein said processor receives an outputsignal from said sensor in response to said collision, said processoractively monitoring said sensor for said output signal in response tosaid collision; and an output signal generator operatively connected tosaid processor, said output signal generator generating an externalindication in response to said collision.
 27. The collision sensorassembly of claim 26, wherein said output signal generator provides arelative location of said collision.
 28. The collision sensor assemblyof claim 26, wherein said housing is attachable to said pallet rack at alocation wherein said housing is contacted during said collision. 29.The collision sensor assembly of claim 28, wherein said sensor islocated within said housing.
 30. The collision sensor assembly of claim26, wherein said sensor is attachable to said pallet rack at a locationwherein said sensor is contacted during said collision.
 31. Thecollision sensor assembly of claim 30, wherein said sensor isspaced-apart from said housing.
 32. The collision sensor assembly ofclaim 26, wherein said output signal generator generates a wirelessoutput data signal indicating said collision.
 33. The collision sensorassembly of claim 32, wherein said wireless output data signal is a textmessage or an email message.
 34. The collision sensor assembly of claim32, wherein said wireless output data signal is received by anapplication on a wireless handheld device.